Air Turbine Starter Controller for Pinion Gear Torque Protection
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Solution Overview
Problem
Existing combustion engine starting systems, such as air turbine starters, face challenges in efficiently initiating rotation without causing damage to the pinion gear due to excessive torque or overspeed conditions, which can lead to starter or engine component breakdowns.
Innovation Solution
A turbine air starter assembly with a controller module that monitors speed and torque parameters, adjusting the rotational speed to prevent exceeding predetermined thresholds, thereby ensuring safe operation and preventing damage during the starting sequence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the rotational speed of the air turbine starter is increased to improve starting efficiency, then the starting capability is improved, but the torque may exceed the predetermined threshold causing damage to the pinion gear
Solution Approach 1:
The controller module continuously monitors the rotational speed of the air turbine starter and compares it against a speed profile. When the speed exceeds the profile, the controller reduces air supply to the turbine, creating a closed-loop feedback system that prevents torque threshold violation while maintaining high starting capability when conditions permit
Solution Approach 2:
The system dynamically adjusts the air supply to the turbine based on real-time speed measurements. The controller modulates the air flow rate according to the monitored speed parameter, enabling the system to adapt its torque output to match the engine's starting requirements without exceeding safe operational limits
2Speed
If the air supply to the turbine is increased to accelerate engine starting, then the starting speed is improved, but overspeed conditions may occur causing starter or engine component breakdown
Solution Approach 1:
The controller module implements continuous speed monitoring during the starting sequence and compares actual speed against a predetermined speed profile. When overspeed conditions are detected, the controller automatically reduces air supply to the turbine, creating a protective feedback mechanism that prevents component breakdown
Solution Approach 2:
The system establishes a speed profile before the starting sequence begins, defining safe speed thresholds in advance. The controller uses this pre-established profile to proactively prevent overspeed conditions by adjusting air supply before dangerous speed levels are reached
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively reduces the occurrence of starter or engine component damage by controlling torque and speed within safe limits, ensuring efficient and reliable engine starting while preventing overspeed conditions.
Implementation Method 1
a rotatable turbine located within the flow path within the interior
Data Source
AI summary
A starter assembly includes a housing defining an interior, a rotatable pinion gear wherein the rotatable pinion gear extends exteriorly of the housing and operably coupling to a combustion engine, a torque sensor providing a torque output indicative of a torque experienced by the pinion gear, and a controller module configured operate a starting sequence for the starter assembly.